LENNOX Package Units(both Units Combined) Manual L0806697

User Manual: LENNOX LENNOX Package Units(both units combined) Manual LENNOX Package Units(both units combined) Owner's Manual, LENNOX Package Units(both units combined) installation guides

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,t_ 2005 Lennox Industries Inc.

Dallas, Texas, USA

INSTALLATION

INSTRUCTIONS

15GCSX SERIES UNITS

GAS PACKAGED UNITS (2-5 TONS)

Armstrong # 38152A081

505,039M

01/08

Supersedes 08/05

_pu Technical

blications

Litho U.S.A.

RETAIN THESE INSTRUCTIONS

FOR FUTURE REFERENCE

Unit Dimensions ............................... 2

Parts Arrangement ............................. 3

Shipping & Packing List ......................... 3

General ....................................... 3

Safety Information .............................. 3

Location Selection .............................. 4

Rigging & Setting Unit .......................... 5

Clearances .................................... 5

Installing Vent Hood ............................ 6

Existing Common Vent Systems ................. 6

Condensate Drain .............................. 7

Filters ......................................... 7

Supply & Return Connections .................... 7

Compressors .................................. 8

Gas Supply and Piping .......................... 8

Electrical ..................................... 10

Blower Control Board .......................... 12

Cooling Start-Up .............................. 14

Heating Start-up .............................. 15

Unit Controls ................................. 16

Condenser Fan Clearances ..................... 18

Maintenance .................................. 20

Repair Parts & Accessories ..................... 20

c( )us -&WARNING GAS-FIRED

o us

LISTED

Do not store or use gasoline or other

flammable vapors and liquids in the

vicinity of this or any other ap-

pliance.

Installation and service must be

performed by a qualified installer,

service agency or the gas supplier.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

•Do not touch any electrical switch; do not

use any phone in your building.

•Leave the building immediately.

•Immediately call your gas supplier from a

neighbor's phone. Follow the gas supplier's

instructions.

•If you cannot reach your gas supplier, call

the fire department.

01/08

IIIHIIIIIIIIIIIIIIIIIIIIIIIIIIlllllll Page 1

505,039M

IIIlllllllllllllllllllllllllllllllllllllll

AA (

2-314

(70)

DOWN-FLOW

RETURN AIR

OPENING

2-1/2 (64)

DOWN-FLOW

BB-r

,iI

u CC

TOP VIEW

FRONT VIEW

GAS PIPING INLET _'X'_

_L---P

Model

Number

.91- 4-1/4 (108)

__I

3-1/4 (83) FLUE

OUTLET

ELECTRICAL INLET "I-

15GCSXAV-24

15GCSXAV-30

15GCSXAV-36

15GCSXAV-42

15GCSXAV-48

15GCSXAV-60

108

112

117

Corner Weights

125 97 15.5

126 105 16

176 140 20

177 144 20

184 151 20

101

136

137

143

Center Of

Gravity

in.

28.5

29.5

33.5

HORIZONTAL E

SUPPLY AIR

OPENING 22

D : E---_ H

2-3/4 2-314

- (70)

(70) K _I- J -_

BACK VIEW

7HORIZONTAL

RETURN

AIR

OPENINGS

(2)

2-1/2 (64) _i _ CONDENSATE DRAIN

END VIEW END VIEW

A B CD E F

Model No. in. mm in. mm in. mm in. mm in. mm in. mm

15GCSXAV-24

15GCSXAV-30 34-1/4 870 65-3/8 1661 36-1/2 927 11-1/4 286 17-1/4 438 20 508

15GCSXAV-36

15GCSXAV-42

15GCSXAV-48 38-1/4 972 75 1905 46 1168 11-1/4 286 19-1/4 489 22 559

15GCSXAV-60

F G H J K L

Model No. in. mm in. mm in. mm in. mm in. mm in. mm

15GCSXAV-24

15GCSXAV-30 20 508 8-1/2 216 3 76 20-1/4 514 4-1/2 114 19 483

15GCSXAV-36

15GCSXAV-42

15GCSXAV-48 22 559 9-1/4 241 3-1/4 83 22-1/4 572 4 102 16-1/4 413

15GCSXAV-60

Page 2

PureAir_Gas Valve

Air Purification System

(Optional) \

\\ \

Ignition Control

Board Condenser

Coil

Evaporator

Coil

Control Box

Variable

Speed

Blower Motor Gas

Manifold Burner Box

Compressor

\\Pressure

Switch

Combustion

Air Inducer

1 - Assembled gas package unit

1 - Vent hood assembly with screen and screws

As soon as the unit is received, it should be inspected for

possible damage during transit. If you find any damage, im-

mediately contact the last carrier.

Ak WARNING

These installation instructions are intended as a general

guide only, for use by an experienced, qualified contractor.

The 15GCSX units are single-package air conditioners

with two-stage gas heat designed for outdoor installation

on a rooftop or a slab.

The unit must be sized based on heat loss and heat gain

calculations made according to the methods of the Air

Conditioning Contractors of America (ACCA).

The units are shipped assembled. All piping, refrigerant

charge, and electrical wiring are factory-installed and

tested. The units require electric power, gas piping,

condensate drain and duct connections at the point of

installation. In addition, the heating vent hood must be

installed before the unit is placed into operation

,CAUTION

&IMPORTANT

Page 3

,&, WARNING

These units must be installed in accordance with all

applicable national and local safety codes,

These instructions are intended as a general guide and do

not supersede local codes in any way, Consult authorities

having jurisdiction before installation.

If components are to be added to a unit to meet local codes,

they are to be installed at the dealer's and/or customer's

expense.

These units are design listed by UL in both the United

States and Canada as follows:

•- For use as a forced air furnace with cooling,

• - For outdoor installation only,

• - For installation on combustible material,

• - For use with natural gas or L.P,/propane gas only. Use

of L.P./propane gas requires installation of an L,P,

conversion kit, which must be ordered separately.

These units are not suitable for use with conventional

venting systems.

The following safety requirements must also be met when

the 15GCSX units are installed:

1 - Use only with the type of fuel approved for use with this

appliance, Refer to the unit rating plate,

2 - Position, locate and install the 15GCSX unit only as

outlined in these instructions.

3 - Provide adequate clearance around the vent hood as

specified in these instructions.

4 - Do not use an open flame to check for gas leaks. Use a

commercially available soap solution, which has been

designed specifically to check for gas leaks, Refer to

the Gas Supply and Piping section,

5 - Check the unit operation after start-up to make sure

that the 15GCSX is operating within the intended tem-

perature rise range. The duct system must be de-

signed to provide an external static pressure within the

allowable range, Refer to the unit rating plate,

Lennox does not recommend the use of 15GCSX units as a

construction heater during any phase of construction, Very

low return air temperatures, harmful vapors and operation

of the unit with clogged or misplaced filters will damage the

unit,

15GCSX units may be used for heating of buildings or

structures under construction, if the following conditions

are met:

•The vent hood must be installed per these installation in-

structions.

• A room thermostat must control the furnace, The use of

fixed jumpers that will provide continuous heating is not

allowed.

• The return air duct must be provided and sealed to the

furnace.

• Return air temperature range between 60°F (16°C) and

80°F (27°C) must be maintained.

• Air filters must be installed in the system and must be

maintained during construction.

• Air filters must be replaced upon construction comple-

tion.

• The input rate and temperature rise must be set per the

unit rating plate.

• One hundred percent (100%) outdoor air must be pro-

vided for combustion air requirements during construc-

tion. Installation of this unit in its intended outdoor loca-

tion will accomplish this.

• The heat exchanger, components, duct system, air fil-

ters and evaporator coil must be thoroughly cleaned fol-

lowing final construction clean-up.

• The unit operating conditions (including ignition, input

rate, temperature rise and venting) must be verified ac-

cording to these installation instructions.

NOTE -The Commonwealth of Massachusetts stipu-

lates these additional requirements:

• Gas furnaces shall be installed by a licensed plumb-

er or gas fitter only.

• The gas cock must be "T handle" type.

• When flexible connectors are used, the maximum

length shall not exceed 36".

Use the following guidelines to select a suitable location for

these units,

1 - Unit is designed for outdoor installation only. Unit must

be installed so all electrical components are protected

from water.

2 - Condenser coils must have an unlimited supply of air.

3 - For ground level installation, use a level pre-fabricated

pad or use a level concrete slab with a minimum thick-

ness of 4 inches. The length and width should be at

least 6 inches greater than the unit base, Do not tie the

slab to the building foundation.

4 - Maintain level within a tolerance of 1/4 inch maximum

across the entire length or width of the unit,

Page 4

5- Donotlocatetheunitwherethecombustionairsupply

willbeexposedtoanycorrosivesubstance,including

thefollowing:

Permanentwavesolutions,

Chlorinatedwaxesorcleaners,

Chlorine-basedswimmingpoolchemicals,

Water-softeningchemicals,

De-icingsaltsorchemicals,

Carbontetrachloride,

Halogen-typerefrigerants,

Cleaningsolvents(e.g.,perchloroethylene),

Printinginks,paintremovers,varnishes,etc.,

Cementsandglues,

Anti-staticfabricsoftenersusedinclothesdryers,

Masonryacid-washingmaterials,

Chlorinatedlaundryproducts,

Hydrochloricacid.

Exercisecarewhenmovingtheunit.Donotremoveany

packaginguntiltheunitisneartheplaceofinstallation.An

optionallifting lug kit (92M51)may be purchased

separatelyfor use in riggingthe unit for lifting.The

spreader lengths must exceed the width across the top

of the unit. Recommended spreader lengths: for use with

2, 2-1/2 and 3-ton units -- 44"; for use with 3-1/2, 4 and 5-ton

units -- 54",

CAUTION

Accessory Lift Kit

Figure 1

Units may also be moved or lifted with a forklift while still in

the factory supplied packaging.

NOTE -Length of forks must be a minimum of 42 inches.

Page

All units require certain clearances for proper operation

and service. Refer to figure 2 for the clearances required

for combustible construction, servicing, and proper unit

operation.

NOTE -Do not permit overhanging structures or shrubs to

obstruct condenser air discharge outlet or vent outleL

Service Clearances

36 (914)

48 (1219)

NOTE - Top Clearance - 36 in. (914 mm)

NOTE - Entire perimeter of unit base requires

support when elevated above mounting surface.

Figure 2

In the U.S. units may be installed on combustible flooring

made from wood or class A, B, or C roof covering material.

In Canada, units may be installed on combustible flooring.

The products of combustion are discharged through a

screened vent outlet in the front mullion.

Install the unit so that the products of combustion will not

damage the outer building structure.

The vent outlet must be at least 4 feet below, 4 feet

horizontally from and 1 foot above any door, window or

gravity air inlet into the building. In addition, install the unit

so that the vent outlet is at least 3 feet above any forced air

inlet located within 10 feet.

Clearances to the vent outlet must also be consistent with

the requirements of the current National Fuel Gas Code

(Z223.1) and/or the standards of the current CSA B149

codes.

Figure 3 shows the minimum clearances to combustibles

required above and below the vent hood. The minimum

clearance in front of the vent hood is 24 inches.

Install the unit so that snow accumulation will not restric the

flow of the flue products. Allow a required minimum

horizontal clearance of 4 feet from electric meters, gas

meters, regulators and relief equipment. In addtion to the

above requirements, ensure that unwanted ice caused by

condensate is not allowed to accumulate around the unit.

Do not locate the unit on the side of the building where the

prevailing winter winds could trap moisture, causing it to

freeze on the walls or on overhangs (under eaves). The

vent outletshouldnot dischargeflue productson a

sidewalk,patioor otherwalkwaywherethe condensate

couldcausethesurfacetobecomeslippery,

Do not install the unit so that the products of

combustionwill be allowedto accumulatewithin a

confinedspaceandrecirculate.

Minimum Clearances to Combustible Materials

Above and Below Vent Hood

Minimum Clearance

Above Vent Hood:

Distance from Top

of Vent Hood

to Top of Unit

Minimum Clearance

Below Vent Hood:

Distance from Bottom

of Vent Hood to Base

of Unit

Figure 3

The vent hood, screen and screws are shipped inside the

unit in the plastic bag which contains the installation

instructions,

1 - Insert the vent screen into the vent tube Once in-

serted, the screen should be flush with the end of the

tube as shown in figure 4.

Vent Hood Installation

Front View Top View

_Vent Tube

NOTE -

Screws

Vent Tube should pass

Screen is pre-formed Vent Hood through

sides of

screen to

hold screen

__ in place.

i Slotted side of

vent hood faces

condenser coil.

Figure 4

2 - Position the vent hood over the vent tube so that the

slotted side of the hood faces the condenser coil. Use

the four sheet metal screws (provided) to secure the

vent hood to the vent tube. The screws should pass

through the sides of the screen in order to hold the

screen in place.

The vent hood must be installed prior to unit start-up.

If the 15GCSX unit is replacing an existing furnace which is

being removed from a venting system commonly run with

separate gas appliances, the venting system is likely to be

too large to properly vent the remaining attached ap-

pliances.

Conduct the following test while each appliance is operat-

ing and the other appliances (which are not operating) re-

main connected to the common venting system. If the vent-

ing system has been installed improperly, you must

correct the system as indicated in the general venting re-

quirements section.

1 - Seal any unused openings in the common venting sys-

tem.

2 - Inspect the venting system for proper size and horizon-

tal pitch. Determine that there is no blockage, restric-

tion, leakage, corrosion, or other deficiencies which

could cause an unsafe condition.

3 - Close all building doors and windows and all doors be-

tween the space in which the appliances remaining

connected to the common venting system are located

and other spaces of the building. Turn on clothes dry-

ers and any appliances not connected to the common

venting system. Turn on any exhaust fans, such as

range hoods and bathroom exhausts, so they will oper-

ate at maximum speed. Do not operate a summer ex-

haust fan. Close fireplace dampers.

4 - Follow the lighting instructions. Turn on the appliance

that is being inspected. Adjust the thermostat so that

the appliance operates continuously.

5 - After the main burner has operated for 5 minutes, test

for leaks of flue gases at the draft hood relief opening.

Use the flame of a match or candle, or smoke from a

cigarette, cigar, or pipe.

6 - After determining that each appliance connected to the

common venting system is venting properly, (step 3)

return all doors, widows, exhaust fans, fireplace damp-

ers, and any other gas-burning appliances to their pre-

vious mode of operation.

7 - If a venting problem is found during any of the preced-

ing tests, the common venting system must be modi-

fied to correct the problem.

Resize the common venting system to the minimum

vent pipe size determined by using the appropriate

tables in Appendix G. (These are in the current stan-

dards of the National Fuel Gas Code

ANSl-Z223.1/NFPA 54 in the USA, and the appropri-

ate Category 1 Natural Gas and Propane appliances

venting sizing tables in the current standards of the

CSA B149 Natural Gas and Propane Installation

Codes in Canada.)

Page 6

The15GCSXunitisequippedwitha 3/4inchFPTcoupling

forcondensatelineconnection.Plumbingmustconformto

local codes.Use a sealingcompoundon malepipe

threads.

Thedrainlinemustbeproperlytrappedandroutedtoa

suitabledrain.Seefigure5forproperdrainarrangement.

Thedrainlinemustpitchto anopendrainor pumpa

minimumof 1inchper10feetto preventcloggingofthe

line.Thedrainlinemustbesupportedso thatweightof

drainlineis not carriedby drainlineconnection.Seal

arounddrainconnectionwithsuitablematerialto prevent

airleakageintoreturnairsystem.

Drainpipingshouldnotbesmallerthandrainconnectionat

coil.Anopenventindrainlinewillsometimesberequired

dueto line length,frictionand staticpressure.Drains

shouldbeconstructedinamannertofacilitatefutureclean-

ing.

NOTE -The condensate drain line MUST be trapped to

provide proper drainage.

CAUTION

vent

Trap must be deep enough to offset maximum

static difference (Generally, 3 inches minimum).

Typical Condensate Drain

Minimum Pitch

1 in. (25 ram) per

10' (3 m) of line unit

open

mounting

frame

Figure 5

Table 1

Unit Filter Size

Unit Model Filter Size Filter Quantity

-24, -30, -36 20 in. X 25 in. 1

-42, -48, -60 16 in. X 25 in. 2

The Healthy Climate ® PureAir ¢ air purification system

(PCO20-28) may be used with 15GCSX units installed in

horizontal air discharge applications only. Installation

hardware kit (Y0629)is required to install the PCO20-28

(X8787) in the packaged unit. The PCO20-28 is designed

for universal voltage, and is ready to operate at 208/230V.

When used, the PCO should be installed before the unit is

set in place and before the duct connections are made.

The duct system should be designed and sized according

to the methods in Manual Q of the Air Conditioning

Contractors of America (ACCA).

A closed return duct system shall be used. This shall not

preclude use of economizers or outdoor fresh air intake. It

is recommended that supply and return duct connections

at the unit be made with flexible joints.

The supply and return air duct systems should be designed

for the CFM and static requirements of the job. They

should NOT be sized by simply matching the

dimensions of the duct connections on the unit.

CAUTION

The 15GCSX unit is shipped ready for horizontal air

discharge (side duct connections). If bottom air discharge

is desired, the covers must be removed from the supply

and return air openings on the bottom of the unit and

re-installed to cover the side openings.

The upper return air opening cover must be removed when

the PureAir ¢ air purification system (PCO20-28) is being

used. In PCO applications, both upper and lower return air

openings must be covered by the return air plenum to

ensure proper PCO operation. The upper return air

opening is not required in horizontal applications when the

PCO is not used.

Filters are not factory-supplied with the unit; however,

optional internally installed filter kits are available. Filter kit

92M54 is used with 2, 2-1/2 and 3-ton units. Filter kit 92M55

is used with 3-1/2, 4 and 5-ton units. The filter kits

accommodate the use of 1", 2" or 4" filters. If the optional

filter kit is not used, a filter must be field-installed.

Filters must always be installed ahead of evaporator coil

and must be kept clean or replaced. Dirty filters will reduce

the airflow of the unit. Filter sizes are shown in table 1.

Removing Supply and Return

Air Opening Covers

1. Remove screw and lift. Base----_ _ I

2. Slide cover to free back pin.

Figure 6

Page 7

Units are shippedwith the compressormountings

factory-adjustedandreadyforoperation.

CAUTION

Check the unit rating plate to confirm whether unit is

equipped for use with natural gas or LP/propane. If

conversion is required use the approved conversion kit.

NQ TE -Units are shipped equipped for natural gas, but can

be converted to LP/propane with a conversion kit. Conver-

sion must be performed by an approved licensed pipe

fitter or technician.

All LP/propane gas equipment must conform to the safety

standards of the National Fire Protection Association.

Complete information regarding tank sizing for

vaporization, recommended regulator settings, and pipe

sizing is available from most regulator manufacturers and

LP/propane gas suppliers.

Proper sizing of gas piping depends on the cubic feet per

hour of gas flow required, specific gravity of the gas and

length of run. In the United States, the current National Fuel

Gas Code Z223.1 should be followed in all cases unless

superseded by local codes or gas company requirements.

Refer to tables 2 and 3. In Canada, refer to the current CSA

B.149 installation codes.

Table 2

Gas Heat Application Data

Unit Input Rating Output Rating Gas Capacity*

Heating Size (Btu) (Btu) (FT3/HR)

68 67,500 54,000 63

83 82,500 66,000 77

90 90,000 72,000 84

110 110,000 88,000 102

138 137,500 110,000 128

*Based on 1075Btu per cubic foot of natural gas.

Before connecting piping, check with gas company or au-

thorities having jurisdiction for local codes or requirements,

When installing gas supply piping, length of run from gas

meter must be considered in determining pipe size for 0.5

inch w.c, maximum pressure drop, Do not use supply pipe

smaller than unit gas connection, For natural gas unit, sup-

ply pressure at the unit gas connection must be a minimum

of 5 inches w.c. and a maximum of 10.5 w.c. For LP/pro-

pane gas units, supply pressure at the unit gas connection

must be a minimum of 11 inches w.c. and a maximum of

13.0 inches w.c.

Table 3

Gas Pipe Capacity-FT 3/HR

Nominal Iron Pipe Size (inches)

Lengthin Feet 1/2 in.

10 132

20 92

30 73

40 63

50 56

60 50

70 46

80 43

90 40

100 38

3/4in. 1 in.

278 520

190 350

152 285

130 245

115 215

105 195

96 180

90 170

84 160

79 150

1-1/4 in.

1050

730

590

5OO

440

400

370

350

320

305

The gas supply piping should be routed through the grom-

met on the side of the unit. Refer to figure 7.

Gas Piping and Electrical Conduit Access

Gas

Thermostat/_'(_/_(_)

Entry J o

Line Voltage

Entry

Figure 7

When making piping connections, a drip leg should be

installed on vertical runs to serve as a trap for sediment or

condensate. A 1/8 inch N.P.T. tap accessible for test gauge

connection must be provided in field piping upstream from

gas supply connection to unit. Install a ground joint union

between gas control manifold and the manual main shut-

off valve. See figure 8.

Compounds used on threaded joints of gas piping shall be

resistant to the action of propane/LP gases.

Page 8

Drip Leg Installation

field provided

1/8 in. !

ground joint

union

manual main

shut-off

unit

I_ leg

gas piping

support

Figure 8

Pressure Test Gas Piping

When pressure testing gas lines, the gas valve must be dis-

connected and isolated. Gas valve can be damaged if sub-

jected to more than 0,5 psig (14 inch w,c,), See figure 9.

If test pressure is equal to or less than 0,5 psig (14 inch

w,c,) shutoff the manual main shut-off valve before pres-

sure testing to isolate unit from gas supply system,

Isolate Gas Valve To Pressure Test

Manual Main Shut-off Valve Will Not Hold Test

Pressures in Excess of 0.5 PSIG (14 in. w.c.)

unit

cap

gas valve

Figure 9

NOTE -Codes may require that manual main shut off valve

and union (furnished by installer) be installed in gas line ex-

ternal to unit. Union must be of the ground joint type.

, WARNING

After gas piping is complete, carefully check all piping con-

nections (factory and field) for gas leaks, Use soap solution

or other preferred means.

NOTE -In case of emergency shutdown, shut off main

manual gas valve and disconnect main power to unit,

These devices should be properly labeled by installer,

The heating value of the gas may differ with locality, The

value should be checked with the local gas utility.

NOTE -There may be a local gas utility requirement speci-

fying a minimum diameter for gas piping. All units require a

1/2 inch pipe connection at the gas valve.

Gas piping recommendations:

-&CAUTION

1 - A drip leg and a ground joint union must be installed in

the gas piping,

A ground joint union is recommended by the manifold/

valve.

2 - When required by local codes, a manual shut-off valve

may have to be installed outside of the unit,

3 - Use pipe thread sealing compound resistant to pro-

pane gas sparingly on male threads,

4 - The gas supply should be a separate line and installed

in accordance with all safety codes. After the gas con-

nections have been completed, open the main shut-off

valve admitting normal gas pressure to the mains,

Check all joints for leaks with soap solution or other

material suitable for the purpose.

Ak CAUTION

5 - The unit and its individual manual shut-off valve must

be disconnected from the gas supply piping system

during any pressure testing dthat system at test pres-

sures in excess of 1/2 PSlG (3.48kPa).

AIMPORTANT

6 - A 1/8 inch N.P.T. plugged tapping, accessible for test

gage connections, must be installed immediately up-

stream of the gas supply connection to the furnace,

Page 9

All wiring should be done in accordance with the

current National Electric Code ANSI/NFPA No. 70 in

the United States. In Canada, wiring must be done in

accordance with the current CSA C22.2 Part 1. Local

codes may take precedence.

Use wiring with a temperature limitation of 75_C min.; run

the 208 or 230 volt, 60 hertz electric power supply through a

fused disconnect switch to control box of unit and connect

as shown in the wiring diagram located on the inside of the

control access panel,

Unit must be electrically grounded in accordance with local

codes or in the absence of local codes with the National

Electric Code, ANSI/NFPA No, 70 (latest edition) or CSA

C22.2 Part 1 (latest edition).

Power supply to the unit must be N.E,C, Class 1, and must

comply with all applicable codes. A fused disconnect

switch should be field provided for the unit, The switch must

be separate from all other circuits, If any of the wire

supplied with the unit must be replaced, replacement wire

must be of the type shown on the wiring diagram.

Electrical wiring must be sized to carry minimum circuit

ampacity marked on the unit. USE COPPER

CONDUCTORS ONLY, Each unit must be wired with a

separate branch circuit and be properly fused.

CAUTION

See figure 10 for field connection of line voltage wiring, See

figure 11 for typical wiring diagram.

208/230 Line Voltage Wiring

contactor

CE_D fused disconnect switch

(furnished by installer)

ground L2

lug

NOTE -ff 208 voltage is suppfied, transformer

connections must be made.

Figure 10

Thermostat

The room thermostat should be located on an inside wall

where it will not be subject to drafts, sun exposure or heat

from electrical fixtures or appliances. Follow

manufacturer's instructions enclosed with thermostat for

general installation procedure, Color coded insulated wires

(# 18 AWG) should be used to connect thermostat to unit,

Four wires are required for cooling,

Heat Anticipator Setting

It is important that the anticipator setpoint be correct. Too

high of a setting will result in longer heat cycles and a

greater temperature swing in the conditioned space,

Reducing the value below the correct setpoint will give

shorter "ON" cycles and may result in the lowering of the

temperature within the conditioned space.

Heat Anticipator Setting: 0.70 AMP

Page 10

(£:I

15GCSX Series Gas Packaged Units

Typical Wiring Diagram

DIAGNOSTIC

LED

BLOWER CONTROL BOARD (A54)

_ HUM

ICMP/N _) CI (RC0m)

AH4103

ADJUST

SELECTOR PINS

(Setting affects both

heating and cooling

modes)

HEATING SPEED

SELECTOR PINS

COOLING SPEED

SELECTOR PINS

WARNING

15GCSX units are equipped with a variable speed motor

that is capable of maintaining a specified CFM throughout

the external static range, A particular CFM can be obtained

by positioning jumpers (COOL, HEAT, and ADJUST) on

the blower control board. The HEAT and COOL jumpers

are labeled A, B, C and D. Each of the numbers corre-

sponds with an air volume (CFM) setting. The ADJUST

jumper is labeled Test, -, +, and Norm. The + and - pin set-

tings are used to add or subtract a percentage of the CFM

selected, The Test jumper is used to operate the motor in

the test mode. See figure 12,

Factory settings for the blower speed jumpers are given in

the wiring diagram in figure 11. Figure 12 shows the blower

control board. Use tables 4, 5 and 6 to determine the cor-

rect air volume for operation in heat and cool mode,

The CFM LED located on the blower control board flashes

one time per 100 cfm to indicate selected blower speed,

For example, if the unit is operating at 1000 CFM, CFM

LED will flash 10 times, If the CFM is 1150, CFM LED will

flash 11 full times plus one fast or half flash.

At times the light may appear to flicker or glow. This takes

place when the control is communicating with the motor be-

tween cycles, This is normal operation,

Read through the jumper settings section before adjusting

the jumper to obtain the appropriate blower speed,

Figure 12

To change jumper positions, gently pull the jumper off the

pins and place it on the desired set of pins, The following

section outlines the different jumper selections available

and conditions associated with each one, Refer to figure

12,

After the CFM for each application has been determined,

the jumper settings must be adjusted to reflect those given

in tables 4, 5 and 6, From the tables, determine which row

most closely matches the desired CFM Once a specific

row has been chosen (% NORMAL, or-), CFM volumes

from other rows cannot be used, Below are descriptions of

the jumper selections,

The variable speed motor slowly ramps up to and down

from the selected air flow during both cooling and heating

demand, This minimizes noise and eliminates the initial

blast of air when the blower is initially energized.

ADJUST

The ADJUST pins allow the motor to run at normal speed,

approximately 15 percent higher, or approximately 15 per-

cent lower than normal speed, Tables 4, 5 and 6 give three

rows (% NORMAL, and -) with their respective CFM vol-

umes. Notice that the normal adjustment setting for heat

speed position C in table 4 is 900 CFM The + adjustment

setting for that position is 1035 CFM and for the - adjust-

ment setting is 765 CFM After the adjustment setting has

been determined, choose the remaining speed settings

from those offered in the table in that row.

The TEST pin is available to bypass the blower control and

run the motor at approximately 70 percent to make sure

that the motor is operational. This is used mainly in trouble-

shooting, The G terminal must be energized for the motor

to run,

Page 12

COOL

TheCOOLjumperis usedto determinetheCFMduring

coolingoperation.Thisjumperselectionis activatedfor

coolingwhenY1isenergized,

Theblowermotorrunsat80percentoftheselectedairflow

forthefirst7-1/2minutesofeachcoolingdemand,Thisfea-

tureallowsforgreaterhumidityremovalandsavesenergy,

In the coolingmode,the blowercontrolboarddelays

bloweroperationfor5secondsafterthecompressorstarts.

Theblowercontinuestooperatefor90secondsafterthe

compressorisde-energized,

HEAT

TheHEATjumperis usedto determineCFMduringgas

heatoperationonly.Thesejumperselectionsareactivated

onlywhenW1isenergized,

In the heatingmode,the blowercontrolboarddelays

bloweroperationfor 30 secondsafter the flame is

established,The blowercontinuesto operatefor 90

secondsafterthegasvalveisde-energized,

CONTINUOUSFAN

Whenthethermostatissetfor"ContinuousFan"operation

andthereisnodemandforheatingorcooling,theblower

controlwillprovide50percentoftheCOOLCFMselected,

NQ TE -With the proper thermostat and subbase, continu-

ous blower operation is possible by closing the R to G cir-

cuit, Cooling blower delay is also functional in this mode.

DEHUMIDIFICATION

The blower control board includes an HUM terminal which

provides for connection of a humidistat. The JV1 resistor

on the blower control board must be cut to activate the

HUM terminal, The humidistat must be wired to open on

humidity rise, When the dehumidification circuit is used,

the variable speed motor will reduce the selected air flow

rate by 25 percent when humidity levels are high. An LED

(D1) lights when the blower is operating in the dehumidifi-

cation mode,

ADJUST

Jumper

Setting

NORM

cfm L/s

1150 545

1000 470

850 400

"COOL" Speed

B C

cfm L/s cfm L/s

920 435 690 325

800 380 600 285

680 320 510 240

Table 4

15GCSXAV-24, 15GCSXAV-30 Blower Performance

0through 0.80 in. w.g. (0 through 200 Pa) External Static Pressure Range

Jumper Speed Positions

"HEAT" Speed

cfm L/s

1035 490

900 425

765 360

cfm L/s

1265 595

1100 520

935 440

cfm L/s

1150 545

1000 470

850 400

cfm L/s

1035 490

900 425

765 360

cfm L/s

920 435

800 380

680 320

"CONTINOUS FAN" S

A B

cfm L/s cfm L/s

575 270 460 215

500 235 400 190

425 200 340 160

cfm L/s

345 165

300 140

)eed

cfm L/s

520 245

450 210

385 180

ADJUST

Jumper

Setting

NORM

cfm L/s

1380 650

1200 565

1020 480

Table 5

15GCSXAV-36 Blower Performance

0through 0.80 in. w.g. (0 through 200 Pa) External Static Pressure Range

Jumper Speed Positions

"COOL" Speed "HEAT" Speed "CONTINOUS FAN" Speed

cfm L/s

1150 545

1000 470

850 400

cfm L/s

920 435

800 380

680 320

cfm L/s

1265 575

1100 520

935 440

cfm L/s

1555 735

1350 635

1150 540

cfm L/s

1265 595

1100 520

935 440

cfm L/s

1150 545

1000 470

850 400

cfm L/s

1035 490

900 425

765 360

cfm L/s

690 325

600 285

510 240

ufm L/s

575 270

500 235

425 200

C D

cfm L/s cfm L/s

460 215 635 300

400 190 550 260

350 165 470 220

"AD-

JUST"

Jumper

Setting

NORM

cfm L/s

2070 975

1800 850

1530 720

Table 6

15GCSXAV-42, 15GCSXAV-48, 15GCSXAV-60, Blower Performance

0 through 0.80 in. w.g. (0 through 200 Pa) External Static Pressure Range

Jumper Speed Positions

"COOL" Speed "HEAT" Speed "CONTINOUS FAN" S 3eed

cfm L/s

1840 870

1600 755

1360 640

cfm L/s

1610 760

1400 660

1190 560

cfm L/s

1380 650

1200 565

1020 480

cfm L/s

2015 950

1750 825

1490 700

cfm L/s

1900 895

1650 780

1405 660

cfm L/s

1555 735

1350 635

1150 540

cfm L/s

1325 625

1150 545

980 460

cfm L/s

1035 490

900 425

765 360

cfm L/s

920 435

800 380

680 320

C D

cfm L/s cfm L/s

805 380 690 325

700 330 600 285

595 280 510 240

Page 13

Thecoolingsectionisacompletefactorypackageutilizing

anair-cooledcondenser.Thesystemisfactory-charged

withR-410Arefrigerant.Thecompressoris hermetically

sealed, internally sprung and base-mountedwith

rubber-insolatedhold-downbolts.

Pre-Start Check List:

1 - Make sure refrigerant lines do not rub against the cabi-

net or each other.

2- Inspect all electrical wiring, both factory- and field-

installed, for loose connections.

3 - Check voltage at the disconnect switch. Voltage must

be within the range listed on the unit nameplate. If not,

consult power company and have voltage condition

corrected before starting unit.

4 - Recheck voltage with unit running. If power is not with-

in the range listed on the unit nameplate, stop the unit

and consult the power company. Check unit amper-

age. Refer to unit nameplate for correct running amps.

5 - Make sure filter is in place before unit start-up.

6 - Before placing the unit into full operation, energize the

unit for three false starts. Energize the compressor

just long enough for it to make a few revolutions, wait

five to seven minutes before repeating a second and

third time.

Cooling Sequence of Operation

When the thermostat calls for cooling, "R" is closed to "G"

and "Y" (figure 11). This completes the low voltage control

circuit, energizing the compressor, condenser fan motor

and blower motor.

NOTE -At the start of the each cooling demand, the

combustion air blower (draft motor) will operate for 10

seconds.

Unit compressors have internal protection. If there is an

abnormal rise in the compressor temperature, the

protector will open and the compressor will stop.

Blower Delay - Cooling

In the cooling mode, the circulating air blower operation is

delayed for 5 seconds after the compressor starts. The

blower continues to operate for 90 seconds after the

compressor is de-energized.

NOTE -With the proper thermostat and subbase, continu-

ous blower operation is possible by closing the R to G cir-

cuit. Cooling blower delay is also functional in this mode.

System Performance

For maximum performance of this cooling system, the

operating temperatures and pressure should be checked

and superheat determined at Standard ARI test conditions

of 82 '_F outdoor temperature with minus (-)80 '_ F indoor

dry bulb /67 _ F indoor wet bulb. If superheat measured

deviates from values in table 7, refrigerant charge should

be adjusted accordingly for maximum performance.

Table 7

Suction Superheat Values

Suction Superheat

Unit Model No. 82°F OD minus 80"F IDDB

/67"F IDWB

15GCSX-24 15 o

15GCSX-30

15GCSX-36 12°

15GCSX-42

15GCSX-48 10 °

15GCSX-60

Verify system performance using table 8 as a general

guide. Table 8 should not be used for charging unit. Minor

variations in these pressures may be expected due to dif-

ferences in installations. Significant differences could

mean that the system is not properly charged or that a prob-

lem exists with some component in the system.

Used carefully, this table could serve as a useful service

guide. Data is based on 80°F dry bulb /67°F wet bulb return

air. Allow unit operation to stabilize before taking pressure

readings.

Table 8

Normal Operating Pressures

80°F db /67°F wb RETURN AIR Air Temperature Entering Outdoor Coil (°F)

UNIT PRESSURE 65 70 75 80 82 85 90 95 100 105 110 115

15GCSX-24 142 143 144 146 146 147 148 149 150 151 152 153

15GCSX-30 134 136 138 140 141 142 144 146 148 149 151 152

15GCSX-36 143 144 146 147 148 149 151 152 155 155 157 157

Suction

15GCSX-42 140 140 140 141 141 141 142 142 143 144 145 147

15GCSX-48 140 141 142 144 144 145 146 147 148 149 150 151

15GCSX-60 143 144 145 146 146 147 147 148 149 150 151 152

15GCSX-24 219 242 264 287 296 310 333 355 379 398 430 457

15GCSX-30 232 255 277 300 309 323 345 368 390 408 440 470

15GCSX-36 244 268 292 316 326 340 363 369 410 429 461 493

15GCSX-42 Liquid 225 247 269 291 300 314 337 357 383 402 434 457

15GCSX-48 243 264 285 307 315 328 349 370 391 408 440 470

15GCSX-60 257 280 303 326 335 349 372 395 418 436 468 497

Page 14

Pre-Start Check List:

1 - Check the type of gas being supplied, Be sure it is the

same as listed on the unit nameplate,

2 - Make sure the vent hood has been properly installed,

FOR YOUR SAFETY READ BEFORE LIGHTING

BEFORE LIGHTING smell all around the appliance area

for gas, Be sure to smell around the base of the unit be-

cause some gas is heavier than air and will settle down low,

,WARNING

WARN ING

Use only your hand to turn the gas valve knob, Never use

tools. If the knob will not move by hand, do not try to repair

the gas valve. Call a qualified service technician, Force or

attempted repair may result in a fire or explosion,

This furnace is equipped with a direct ignition control, Do

not attempt to manually light the burners,

1 - Turn off electrical power to unit.

2 - Set thermostat to lowest setting.

3 - Turn the gas valve knob to the ON position, Refer to

figure 13,

4 - Turn on electrical power to unit,

5 - Set room thermostat to desired temperature, (If ther-

mostat setpoint temperature is above room tempera-

ture after the pre-purge time expires, main burners will

light),

Honeywell VR8205 Series Gas Valve

HIGH FIRE

ADJUSTING SCREW

(under cap)

OUTLET

(MANIFOLD)

TAP

LOW FIRE

(under cap)

INLET ._URE

TAP

GAS VALVE SHOWN IN OFF POSITION

Figure 13

To Shut Down:

1 - Turn off electric power to unit.

2 - Turn the gas valve knob to the OFF position.

Post Start-up Check List (Gas)

After the control circuit has been energized and the heating

section is operating, make the following checks:

1 - Use soap solution to check for gas leaks in the unit pip-

ing as well as the supply piping,

2 - Check for correct manifold gas pressures, See "Man-

ifold Gas Pressure Adjustment."

3 - Check the supply gas pressure. It must be within the

limits shown on rating nameplate. Supply pressure

should be checked with all gas appliances in the build-

ing at full fire, At no time should the supply gas pres-

sure exceed 10.5 inches w,c,, nor drop below 5.0 inch-

es w,c. for natural gas units, For propane gas, supply

gas pressure should not drop below 11 inches w.c. If

gas pressure is outside these limits, contact your gas

supplier for corrective action.

4 - Adjust temperature rise to the range specified on the

rating plate,

Checking and Adjusting Gas Input

NQ TE -Units must be converted for use with LP/propane

gas. Conversion kit is ordered separately. Conversion

must be performed by an approved licensed pipe fitter

or technician.

The minimum permissible gas supply pressure is 5,0

inches W.C. for natural gas or 11,0 inches W,C. for

LP/propane gas, The maximum inlet gas supply pressure

is 10.5 inches W,C, for natural gas and 13,0 inches W.C. for

LP/propane gas, Gas input must never exceed the input

capacity shown on the rating plate,

Units fueled by natural gas are rated for manifold pressures

of 2,0 inches W,C, for first stage and 3,5 inches W,C. for

second stage,

Page 15

Unitsfueledby LP/propanegasare ratedfor manifold

pressuresof5.6inchesW.C.forfirststageand10.0inches

W.C.forsecondstage.

Measuremanifoldpressure:Shutoffgassupplyto the

unit. Removeplugfrom pressuretap. Seefigure 13.

Connectmanometerorgaugetotheproperpressuretap,

thenturnonthegassupply.

TheHoneywellVR8205gasvalvehasseparateadjusting

screwsfor firststage(LO)andsecondstage(HI).The

adjustingscrewsare positionedon eitherside of the

barbedfitting.Turnthe adjustingscrewsclockwiseto

increasepressureand input;turn counterclockwiseto

decreasepressureand input. The pressureregulator

adjustmentis sensitive.Oneturnof theadjustingscrew

resultsina largechangeinmanifoldpressure.

Finalfirst-stageand second-stagemanifoldpressures

mustbewithintheallowablerangersfor thegas being

used.

ForNaturalGas:Checkthefurnaceratebyobservinggas

meter,makingsureallothergasappliancesareturnedoff.

Thetesthandonthemetershouldbetimedforatleastone

revolution,Notethenumberofsecondsforonerevolution,

BTU/HR = Cubic Feet Per Revolution X 3600 X Heating Value

INPUT No. Seconds Per Revolution

The heating value of your gas can be obtained from your

local utility.

For LP/Propane Gas: If a gas meter is available, check the

input rate as described in the section above. Heating value

of propane gas is available from propane supplier. Other-

wise, the only check for the output rate is to properly adjust

the manifold pressure using a manometer. Typical man-

ifold setpoint for installations at altitudes from 0 to 4500 feet

above sea level is 10.0 inches W.C.

High Altitude Information

Ratings shown on the rating plate for elevations up to 4,500

feet. For elevations above 4,500 feet, ratings should be

reduced at a rate of four percent for each 1,000 feet above

sea level. See National Fuel Gas Code Z223.1 (latest

edition) or the requirements of the CSA B149 installation

codes.

Heating Sequence of Operation

When the thermostat calls for heating, Wl is energized.

NOTE -The ignition control ignores a carl for second-stage

heat until first-stage heat has been established.

The ignition control checks high temperature limit and

rollout switches to make sure they are closed. The control

then verifies that the pressure switch is open. If the

pressure switch is closed, the control will flash code 3 on

the LED and will wait indefinitely for the pressure switch to

open. If the pressure switch is open, the control proceeds

to the 15-second pre-purge.

The ignition control energizes the combustion air inducer

on high speed, flashes a code 3 on the LED, and waits for

the pressure switch to close.

When the pressure switch has closed, the LED code 3 flash

stops and the control begins the 15-second pre-purge

period. When the pre-purge time has expired, the control

begins the ignition trial.

The ignition control energizes the gas valve and spark. The

control ignores the flame sense signal for the first two

seconds of the ignition trial. If the flame is established

within 10 seconds, the control de-energizes the spark. If

flame is not established within 10 seconds, the gas valve

and spark are de-energized and the ignition control

initiates a 30-second inter-purge sequence.

Approximately 30 seconds after the flame has been

established, the circulating air blower starts and the

combustion air inducer is switched to low speed. The

ignition control inputs are continuously monitored to

ensure that limit switch(es), rollout switch and pressure

switch are all closed, and that the flame remains

established and heating demand is present. First-stage

gas valve, low-speed combustion air inducer and

circulating blower remain energized. If the thermostat

signals a requirement for second-stage heat (W2), the

ignition control initiates high heat operation.

When a signal for second stage heat is received by the

ignition control, the control energizes the second-stage

gas valve and high-speed combustion air inducer until the

demand is satisfied.

If a first-stage heat demand continues after the

second-stage heat demand has been satisfied, the ignition

control immediately de-energizes the second-stage gas

valve. The combustion air inducer is held in high speed

operation for an additional 1 second after the second-stage

gas valve is de-energized. First-stage heat operation

(first-stage gas valve and low-speed combustion air

inducer) continues until heating demand is satisfied.

When the heating demand is satisfied, the control

immediately de-energizes the gas valve. The combustion

air inducer remains energized for a 30-second post-purge

period. The circulating air blower operates for 90 seconds

after the gas valve is de-energized.

Blower Delay - Heating

In the heating mode, the circulating air blower operation is

delayed for 30 seconds after the flame is established. The

blower continues to operate for 90 seconds after the gas

valve is de-energized.

NOTE -With the proper thermostat and subbase, continu-

ous blower operation is possible by closing the R to G cir-

cuit.

Blower Control Board (A54)

15GCSX units are equipped with a variable speed motor

which is controlled by a blower control board. Blower con-

trol board settings and operation are given on page 12.

Ignition Control Board (A3)

The 15GCSX unit includes an ignition control board which

controls the combustion air inducer, gas valve and spark

electrode. It receives signals from the main and auxiliary

limit switches, the rollout switch, the pressure switch and

the flame sensor. LED codes and flash rates are given on

page 17. The ignition control board is shown in figure 14.

Page 16

Ignition Control Board

i( hill -I;,,°°

CONNECTOR PI

P!N I LIMIT SW}TCB (OUTPUT, COMMON WITH "W" TERMINAL1

P}N 2 GAS VALV _ Z4 VAC COMMON (CHASSIS GROUND}

P}N 5 _OW GAS VALVE OUTPUF

P}N 4 _IMil SW}FCN }NPUF

P}N 5 PRESSURE SWITCH OUIPU]

P}N 6 _OW PRESSURE SWI]CH INPUT

PiN 7 HIGH GAS VALVF OUFPU]

P}N 8 HIGH PRESSURE SW}ICH INPUF (OPFIONAL)

P}N 9 FLAME SENSF INPU]

CONNECTOR P2

'R" 24VAC TO THERMOSTAT

'W" FHERMOS]Aq CALL FOR HEAT

'W2" rHERMOSTAq 2ND SIAGE CALL FOR HEA]

"G" THERMOSTAT CALL FOR CONTINUOUS FAN

'Y" FHEI:_MOSTAI CALL FOR COOLING

QUICK CONNECT TERMINALS

"INDUCER LOW ¸' DRAFT }NDUCER MOTOR OUTPUT

"INDUCER NIGH" 2ND STAGE DRAFT INDUCER MOTOR OUTPUT

"11" (2} 230 VAC LINE }NPUT

"L2" (4) 230 VAC LINE }NPUT

"C" (2} 24 VAC SYSTEM COMMON (GROUND}

"24VAC" CONTINUOUS 24VAC PROM IRANSFORMER

"CIR _' CIRCULATING AIR BLOWER MOTOR

T}M!NGS:

PREPURGE: }5 SECONDS

JGN}T}ON TR}AI I0 SECONDS

INTERPURGE: 30 SECONDS

HEAT SLOWER ON DELAY 30 SECONDS

HEAT SLOWER OFF ¸ DELAY 90 SECONDS

POST PURGE 30 SECONDS

COOL RAN OFF DELAY 90 SECONDS

Figure 14

Ignition Control Board LED Codes

The ignition control board LED flashes codes which indi-

cate normal or abnormal operations:

Slow Flash -- Normal operation, no carl for heat.

One flash per second.

Fast Flash -- Normal operation, call for heat.

Two flashes per second.

Steady Off -- Internal failure or no power.

(Micro-controller failure; self-check.)

Steady On -- Internal control failure.

(Micro-controller failure; self-check).

Code 2 -- System lockout -Failed to detect or sustain

flame.

Two flashes in 1 second with a 1-second pause.

Code 3 -- Pressure switch open with inducer on or

closed with inducer off.

Three flashes in 1-1/2 seconds with a 1-second pause.

Code 4 -- High limit/or rollout switch open.

Four flashes in 2 seconds with a 1-second pause.

Code 5 -- Flame sensed while gas valvede-energized.

Five flashes in 2-1/2 seconds with a 1-second pause.

Code 6 -- Rollout switch is open.

Six flashes in three seconds with a one-second pause.

Limit Control

supply airflow, occurs. The main gas valve is closed. The

circulating air blower will continue to operate until the

blower off delay period has elapsed.

Pressure Switch

If the combustion air inducer motor should fail or if the vent

system is blocked, the pressure switch prevents the gas

valve from being energized.

Spark Electrode and Flame Sensor Rod

The spark electrode and flame sensor rod are part of the

burner assembly. The spark electrode is typically located

on the far-left burner. The flame sensor rod is typically

located on the far-right burner. If the ignition control does

not receive a signal from the flame sensor indicating that

the burners have established flame, the main gas valve will

close after the 10-second ignition trial period built into the

ignition control.

Rollout Switch

The switch is located above the main burners. In the event

of a sustained main burner rollout the main gas valve is

closed. To reset, push the button on top of the switch.

Auxiliary Limit (-42, -48 &-60 units only)

This control is located inside the heating compartment and

is designed to open at abnormally high air temperatures. It

resets automatically. The limit switch operates when a high

temperature condition, caused by inadequate blower

This control is located in the side of the circulating air

blower housing. If the circulating air blower fails to operate,

the temperature rises and opens the auxiliary limit. The

main gas valve closes. This control resets automatically.

Page 17

System Operation Monitor (LSOM)

The system operation monitor (A132) detects the most

common fault conditions in the air conditioning system.

When an abnormal condition is detected, the module com-

municates the specific condition through its ALERT and

TRIP lights. The module is capable of detecting both me-

chanical and electrical system problems, See figure 15 for

the system operation monitor,

System Operation Monitor (A132)

POWER LED

DATA OUTPUT

ALERT LED

TRIP LED

--DATA OUTPUT

CONNECTOR

_'.25"SPADE

CONNECTOR(5)

Figure 15

IMPORTANT

LSOM LED Functions

Power LED (green) -- Voltage within the range of

19-28VAC is present at the system monitor power connec-

tion,

Alert LED (yellow) -- Communicates an abnormal system

condition through a unique flash code. The alert LED

flashes a number of times consecutively; then pauses;

then repeats the process, This consecutive flashing corre-

sponds with a particular abnormal condition.

Trip LED (red) -- Indicates a demand signal from the ther-

mostat; but detects no current to the compressor.

Flash code number -- Corresponds to a number of LED

flashes, followed by a pause, and then repeated,

Trip & Alert LEDs flashing simultaneously -- Indicates that

the control circuit voltage is too low for operation,

Reset ALERT flash code by removing 24VAC power from

monitor. Last ALERT flash code will display for 1 minute af-

ter monitor is powered on.

LSOM codes are given in table 9,

The top of the condenser fan should be 1-1/2 inchs from the

bottom of the top grille, This dimension should be checked

and the fan should be adjusted accordingly any time servic-

ing of the outdoor fan system is required,

Page 18

Table 9

System Operation Monitor LED Troubleshooting Codes

Status LED Description

Module has power

Status LED Condition

Green "Power" LED ON

Green "Power" LED

OFF

Red "Trip" LED ON

Red "Trip" & Yellow

"Alert" LEDs Flashing

Yellow "Alert" Flash

Code 1"

Yellow "Alert" Flash

Code 2*

Yellow "Alert" Flash

Code 3*

Yellow "Alert" Flash

Code 4*

Yellow "Alert" Flash

Code 5*

Module not powering up

System and compressor

check out OK

Thermostat demand signal

Y1 is present, but compres-

sor not running

Status LED Troubleshooting Information

24VAC control power is present at the module terminal.

Determine/verify that both R and C module terminals are connected

and voltage is present at both terminals.

1. Verify Y terminal is connected to 24VAC at contactor coil.

2. Verify voltage at contactor coil falls below 0.5VAC when off.

3. Verify 24VAC is present across Y and C when thermostat

demand signal is present; if not present, R and C wires are reversed.

1. Compressor protector is open.

2. Outdoor unit power disconnect is open.

3. Compressor circuit breaker or fuse(s) is open.

4. Broken wire or connector is not making contact.

5. Low pressure switch open if present in the system.

6. Compressor contactor has failed to close.

Simultaneous flashing. Indicates that the control circuit voltage is too low for operation.

Long Run Time -

Compressor is running

extremely long run cycles

System Pressure Trip -

Discharge or suction

pressure out of limits or

compressor overloaded

Short Cycling - Compres-

sor is running only briefly

Locked Rotor

Open Circuit

aged).

Low refrigerant charge.

Evaporator blower is not running.

Evaporator coil is frozen.

Faulty metering device.

Condenser coil is dirty-

Liquid line restriction (filter drier blocked if present)-

Thermostat is malfunctioning,

High head pressure.

Condenser coil poor air circulation (dirty, blocked, dam-

Condenser fan is not running.

Return air duct has substantial leakage.

If low pressure switch is present, see Flash Code 1 info.

Thermostat demand signal is intermittent.

Time delay relay or control board is defective.

If high pressure switch is present, see Flash Code 2 info.

If low pressure switch is present, see Flash Code 1 info.

Run capacitor has failed.

Low line voltage (contact utility).

Excessive liquid refrigerant in the compressor.

Compressor bearings are seized.

Outdoor unit power disconnect is open.

Unit circuit breaker or fuse(s) is open.

Unit contactor has failed to close.

High pressure switch is open and requires manual reset.

Open circuit in compressor supply wiring or connections.

Unusually long compressor protector reset time due to

extreme ambient temperature.

Compressor windings are damaged.

Yellow "Alert" Flash Open Start Circuit -1. Run capacitor has failed.

Code 6* Current only in run circuit 2. Open circuit in compressor start wiring or connections.

3. Compressor start winding is damaged.

Yellow "Alert" Flash Open Run Circuit - Current 1. Open circuit in compressor start wiring or connections.

Code 7* only in start circuit 2. Compressor start winding is damaged.

Yellow "Alert" Flash Welded Contactor - 1. Compressor contactor failed to open.

Code 8* Compressor always runs 2. Thermostat demand signal not connected to module.

Yellow "Alert" Flash Low Voltage - Control 1. Control circuit transformer is overloaded.

Code 9* circuit <17VAC 2. Low line voltage (contact utility).

*Flash code number corresponds to a number of LED flashes, followed by a pause, and then repeated. Reset ALERT flash code

by removing 24VAC power from monitor; last code will display for 1 minute after monitor is powered on.

Page 19

The GCSX15unitshouldbe inspectedannuallyby a

qualifiedservicetechniciantoensureproperoperation,

Filters

Not supplied. Inspect once a month. Replace disposable,

or clean permanent-type, as necessary. DO NOT replace

permanent type with disposable.

Motors

Indoor, outdoor fan and vent motors are permanently

lubricated and require no further lubrication. Motors should

be cleaned yearly to prevent the accumulation of dust and

dirt on the windings or motor exterior.

Coil

Dirt and debris should not be allowed to accumulate on the

coil surfaces or other parts in the air conditioning circuit.

Cleaning should be performed as often as necessary. Use

a brush, vacuum cleaner attachment, or other suitable

means. If water is used to clean the coil, be sure the power

to unit is shut off prior to cleaning.

NOTE -Care should be used when cleaning the coil so that

the coil fins are not damaged.

Do not permit the hot condenser air discharge to be ob-

structed by overhanging structures or shrubs.

To Clean Burners

Light the burners and allow unit to operate for a few minutes

to establish normal burning conditions. Observe the burner

flames. Compare this observation to figure 16 to determine

if flame is properly adjusted. Flame should be predomi-

nantly blue in color and strong in appearance. Verify that all

burnres are lit and that the flame does not impinge on the

sides of the heat exchanger.

Distorted flame or yellow tipping of the natural gas flame (or

long yellow tips on LP/propane flame) may be caused by

one or more of the following: lint or dirt inside the burner or

burner ports; lint or dirt at the air inlet between the burner

and manifold pipe; or an obstruction over the burner orifice.

Use a soft brush or vacuum to clean the affected areas.

Burner Flame Heat

Burner _L _,/ Exchanger

Gas Burner Flame

Manifold (Blue Only)

Figure 16

Vent Outlet

Visually inspect vent outlet periodically to make sure that

the there is no buildup of soot and dirt. If necessary, clean

to maintain adequate opening to discharge flue products.

The following repair parts are available from your local dealer. When ordering parts, include the complete model number

and serial number which are printed on the unit rating plate.

Controls

Rollout Switch

Transformer

Limit Control

Gas Valve

Ignition Control

Electrode

Flame Sensor

Auxiliary Limit

Pressure Switch

Blower Control

System Operations Monitor

Blower Components

Blower Housing Assembly

Blower Wheel

Blower Motor

Blower Motor Mount

Blower Motor Capacitor (if used)

Combustion Air Inducer

Fan Blade

Fan Motor

Fan Motor Capacitor

Heating Components

Gas Manifold

Main Burner Orifices

Main Burners

Heat Exchanger

Cooling Components

Compressor

Evaporator Coil

Drier

Expansion Valve

Contactor

Capacitor

Condenser Coil

Accessories

Description LENNOX Cat.

Number

LP/Propane Gas Conversion Kit (heat sizes 68 and 90) 92M52

LP/Propane Gas Conversion Kit (heat sizes 83, 110 and 138) 92M56

Filter Kit (2-ton to 3-ton capacity units) 92M54

Filter Kit (3-1/2-ton to 5-ton capacity units) 92M55

PCO20-28 X8787

Installation Hardware Kit for PCO20-28 Y0629

Page 20

LENNOX Package Units(both Units Combined) Manual L0806697

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